Xerox N2825, N2025 Service Manual
Xerox DocuPrint N2025/N2825
CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.
Network Laser Printer Service Manual
XEROX
721P52440
February 2000
This Service Manual contains information
that applies to the DocuPrint N2025/N2825
Laser Printer.
Copyright
This Service Manual contains information that applies to the DocuPrint
N2025/N2825 Electronic Laser Printer.
NOTICE
This manual is for use by Xerox Technicians and Xerox trained
technicians only.
NOTICE
While every care has been taken in the preparation of this manual, no
liability will be accepted by Xerox arising out of any inaccuracies or
omissions.
All service documentation is supplied to Xerox external customers for
informational purposes only. Xerox service documentation is intended
for use by certified, product trained service personnel only. Xerox does
not warrant or represent that such documentation is complete. Nor does
Xerox repr esen t or warr ant t hat it will not ify o r pro vid e to such cu stome r
any future changes to this documentation. Customer’s service of
equipment, or modules, components, or parts of such equipment may
void any otherwise applicable Xerox warranties. If Customer services
such equipment, modules, components, or parts thereof, Customer
releases Xerox from any and all liability for Customer’s actions, and
Customer agrees to indemnify, defend, and hold Xerox harmless from
any third party claims which arise directly or indirectly from such
service.
Prepared by:
Maak 1
105 Loudoun Street S.W.
Leesburg, VA. 20175-2910
Copyright 2000 by Xerox Corporation. Xerox, DocuPrint N2025/N2825
are registered trademarks of Xerox Corporation.
Copyright 2000 Xerox Corporation. All rights reserved.
Copyright protection claimed includes all forms of matters of
copyrightable materials and information now allowed by statutory or
judicial law or hereinafter granted, including without limitation, material
generated from the software programs which are displayed on the
screen such as st yles, templates, icons, screen disp lays, looks, etc.
Xerox, and all product names and product numbers mentioned in this
publication are trademarks.
Adobe and PostScript are trademarks of Adobe Systems Incorporated.
PCL, HP LaserJet, and Intellifont are trademarks of Hewlett-Packard
Company. IBM is a trademark of International Business Machines
Corporation. Microsoft, Microsoft Windows, Microsoft Word, MS, and
MS-DOS are trademarks of Microsoft Corporation. Univers is a
trademark of Linotype AG or its subsidiaries. WordPerfect is a
trademark of WordPerfect Corporation. Centronics is a trademark of
Centronics Corporation. Macintosh and TrueType are trademarks of
Apple Computer, Incorporated. All other product names are trademarks/
tradenames of their respective owners.
PCL, PCL 5e, and PCL 6 are trademarks of Hewlett Packard Company.
This printer contains an emulation of the Hewlett Packard PCL 5e or
PCL 6 command language, recognizes HP PCL 5e or HP PCL 6
commands, and processes these commands in a manner compatible
with Hewlett Packard LaserJet printer products.
XL is a trademark of Xiontics
.
Warning
Prepared for:
Network Printers Business Unit
Customer and Marketing Focus
701 South Aviation Blvd.
El Segundo, California 90245
Copyright
This equipment complies with the requirements in Part 15 of
FCC rules for a class A computing device. Operation of the
equipment in a residential area may cause unacceptable
interference to radio and TV reception, requiring the
operator to take whatever steps are n ecessary to c orrect t he
interference.
02/2000
ii
DocuPrint N2025/N2825
Initial Iss ue
Electrostatic Discharge
Class 1 LASER Product
This caution indicates that there are components which are
sensitive to damage caused by electrostatic discharge.
CAUTION
These components are susceptible
to electrostatic discharge. Observe
all ESD procedures to avoid
damage.
Shock Hazard
This symbol indicates the presence of potentially h azardous
voltages.
FM_001
Fuser Hazard
This symbol indicates the presence of extreme heat from the
Fuser Assembly.
The DocuPrint N2025/N2825 laser printers are certified to
comply with Laser Product Performance Standards set by the
U.S. Department of Health and Human Services as a Class 1
Laser Product. This means that this is a class of laser pr oduct
that does not emit hazardous laser radiation; this is possibl e only
because the laser beam is totally enclosed during all modes of
customer operation.
The laser and output of the laser scanner unit produces a beam
that, if looked into, cou ld cause eye damage. Servic e procedures
must be followed exactly as written without change.
When servicing the machine or laser module, follow the
procedures specified in the manual and there will be no hazards
from the laser.
Laser (FDA): Any laser label visible to service must be
reproduced in the service manual with location shown or
indicated. Safe working procedures and clear warnings
concerning precautions to avoid possible exposure must also be
included.
The Laser contained in the DocuPrint N2025/N2825 meets the
following standard: Laser class 3B, maximum 5mW, wavelength
780nm.
The following LASER symbol will be displayed at the st art of any
procedure where possible exposure to the laser beam exists.
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02/2000
iii
LUOKAN 1 LASERLAITE
KLASS 1 LASER APPARAT
Electrostatic Discharge
Table of Contents
Introduction
Title - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Page
Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - iv
Organization - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - v
Revision Control List - - - - - - - - - - - - - - - - - - - - - - - - - - viii
Service Call Procedures - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-1
Repair Analysis Procedures - - - - - - - - - - - - - - - - - - - - - 2-1
Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-1
Image Quality Repair Procedures - - - - - - - - - - - - - - - - - 3-1
Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1
Repair/Adjustments - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1
Parts List - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5-1
The DocuPrint N2025/N2825 Service Manual is the primary document
used for repairing and maintaining the DocuPrint N2025/N2825 Laser
Printers.
This manual contains Service Call Procedures, Diagnostic Procedures,
General Information, Repair Analysis Procedures, Image Quality
Analysis Procedures, Wiring Data, and Parts Lists that will enable the
Service Representative to repair DocuPrint N2025/N2825 failures.
General Procedures - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 6-1
Wiring Data- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Section Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 7-1
Table of Contents
02/2000
iv
Initial Iss ue
DocuPrint N2025/N2825
Organization
Section 7 - Wiring Data
This manual is divided into seven sections. The title and description of
each section of the manual is as follows:
Section 1 - Service Call Procedures
This section is used to identify a suspected problem. It contains
Machine Orientation, Call Flow, Initial Actions, Corrective Actions, and
Final Actions. This part of the service manual should always be used to
start the service call.
Section 2 - Repair Analysis Procedures
This section is used to isolate and identify problems to a faulty
component or subassembly. It contains the introduction, display
message table, error code tables and the Repair Analysis Procedures
(RAPs).
Section 3 - Image Quality
This section contains image quality repair procedures to assist in
correcting image quality defects. These procedures provide defect
samples and definitions to help identify the type of defect that exists,
the test pattern to use, and actions required to correct the defects.
Section 4 - Repair / Adjustment
This section contains sensor, connector, and PWB location drawings;
power distribution diagrams, interconect diagrams, interconnect
diagrams and pin assignment information. This information is not
specific to individual procedures but is provided for general reference.
This section contains the instructions for removal, replacement, and
adjustment of the spared parts within the machine.
Section 5 - Parts Lists
This section contains illustrations of disassembled subsystems and a
listing of the spared parts.
Part names are listed in this section of the manual even if the part itself
is not spared. All the parts that are spared will have the part number
listed. Parts that are not spared will not have a number listed.
Section 6 - General Procedures
This section includes the Operations Menu Map and the Service Mode
Menu Map. It includes all unique service operations, supplemental tools
and supplies.
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DocuPrint N2025/N2825
02/2000
v
Organization
Terminology and Symbols
FM_001
Shock Hazard
The following is the terminology and symbols that are used in this
manual for Warnings, Electrostatic Device or General Cautions, and
Notes.
Warning
This equipment complies with the requirements in Part 15 of FCC rules
for a class A computing device. Operation of the equipment in a
residential area may cause unacceptable interference to radio and TV
reception, requiring the operator to take whatever steps are necessary
to correct the interference.
Electrostatic Discharge
The following symbols indicates that there are components which are
sensitive to damage caused by electrostatic discharge.
This symbol indicates the presence of potentially hazardous voltages.
Fuser Hazard
This symbol indicates the presence of extreme heat from the Fuser
Assembly.
Terminology and Symbols
02/2000
vi
Initial Iss ue
DocuPrint N2025/N2825
Laser Product Certification
CAUTION
Use of controls or adjustments other than those specified in this manual
may result in an exposure to dangerous laser radiation.
The DocuPrint N2025/N2825 is certified to comply with Laser Product
Performance Standards set by the United States Department of Health
and Human Services as a Class 1 product. This means that it is a laser
product that does not emit dangerous laser radiation during any mode
of customer operation.
During servicing, the laser beam could cause eye damage if looked at
directly. Se rvic e pr oced ure s must be fol lo wed ex actl y as writ ten wi tho ut
change.
These components are susceptible
to electrostatic discharge. Observe
Initial Issue
DocuPrint N2025/N2825
CAUTION
all ESD procedures to avoid
damage.
02/2000
vii
Laser Product Certification
Product:
DocuPrint N2025/N2825 Laser Printer
Title:
Xerox DocuPrint N2025/N2825 Network
Part Number:
721P52440
Laser Printer Service Manual
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Initial Iss ue
DocuPrint N2025/N2825
Page Revision Page Revision Page Revision Page Revision Page Revision Page Revision
Initial Issue
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Revision Control List
1.0 Introduction ............................................................................................................... 1-3
1.1 Machine Orientation.................................................................................................. 1-3
1.2 Call Flow ...................................................................................................................1-4
1.3 Initial Actions .............................................................................................................1-5
1.4 Corrective Actions..................................................................................................... 1-5
1.5 Final Actions.............................................................................................................. 1-8
1 Service Call Procedures
Initial Issue
DocuPrint N2025/N2825
02/2000
1-1
Service Call Procedures
Service Call Procedures
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1-2
Initial Issue
DocuPrint N2025/N2825
1.0 Introduction
The Service Call Procedures section is used to identify a suspected problem. This section contains Call Flow, Initial Actions, Corrective Actions, and Final Actions.
Call Flow illustrates the normal activities and flow of a service call.
Initial Actions are used to gather information regarding the performance of the machine and
prepare the product for servicing.
Corrective Actions are used to verify the normal operation of the machine. In the Y/N (Yes/No)
steps of the corrective actions, a Yes response will lead you to the next step . A No response will
indicate the next step to perform or will direct you to a Repair Analysis Procedure (RAP).
RAPs will provide the instructions to isolate the faulty part or provide a list of suspect parts,
when isolation is not appropriate. Wire harnesses are not included in the repair actions and
problems with loose connections or damaged harnesses should be isolated using visual
inspection and the wiring data in section 7.
Final Actions are used to evaluate the total operation of the system and to identify the actions
required to complete the service call.
1.1 Machine Orientation
For servicing the DocuPrint N2025/N2825, all references to machine orientation are as illustrated in Figure 1.
Figure 1 Machine Orientation
Initial Issue
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02/2000
1-3
Service Call Procedures
1.0, 1.1
1.2 Call Flow
The call flow diagram shows the relationship of actions during a typical service call Figure 1.
The functions in Call Flow correspond to service manual sections as follows:
Section 1 - Initial Actions, Corrective Actions, and Final Actions
Section 2 - Status Indicator Repair Analysis Procedures (RAPs)
Section 3 - Image Quality Repair Analysis Procedures (IQ RAPs)
Section 4 - Repair / Adjustment (REPs)
Section 5 - Parts Lists (PLs)
Section 6 - General Procedures
Section 7 - Wiring
All service calls start with Initial Actions and all service calls end with Final Actions.
Service Call Procedures
1.2
02/2000
1-4
Figure 1 Call Flow Diagram
Initial Issue
DocuPrint N2025/N2825
1.3 Initial Actions
Initial Actions are used to gather information from the operator concerning problems at the
local machine. Make note of symptoms, error messages, error codes or other information concerning the problem that the operator may provide. This information may help identify an intermittent or unusual problem.
Procedure
1. Ensure that the power cord is connected to the wall outlet and to the machine.
2. Check for paper or other objects in the paper path.
3. Remove all paper from the output tray(s).
4. The Rear Cover and Top Cover are closed.
5. The paper is loaded correctly in the Paper Tray(s).
6. Ask the operator to describe, or if possible, demonstrate the problem.
7. If the problem is the result of incorrect operator action, refer the operator to the User documentation or to another customer support function.
8. Refer to Section 2 if an error message is displayed.
9. If possible, print the “Configuration Sheet”. To pr int the Configuration Sheet, press and
release [1] or [5] until “Print Menu” is displayed. Then press and release [2] or [6] until
“Config Sheet” is displayed. Press Enter [4] to print the sheet. If the sheet is blank, go to
IQ RAP 2.
10. Determine that the configuration settings are correct.
11. If possible, print the “Fault History”. To print the “Fault History” press and release [1] or [5]
until “Print Menu” is displayed. Then press and release [2] or [ 6] until “Fault History” is displayed. Next, press Enter [4] to print the sheet. The Fault History will list the error codes
and the meter count when the event happened. Use the Fault History to determine the frequency of a problem. Access the Error Code Tables (Table 1 or Table 2) and perform the
corrective action as instructed.
12. If the Fault History can not be printed, the fault history can be displayed on the Control
Panel. To display the “Fault History” press and release [1] or [5] until “Print Menu” is displayed. Then press and release [2] or [6] until “Display Faults” is displayed. Next, press
press [3] to display the last f ault that occurred. Continue to press and release [3] to display
the error codes in order from the newest to the oldest. Pressing and releasing the [4] key
will display the codes in order from the oldest to the newest. The Display Faults will display the error code and the meter count when the event happened. An example of the display “E9-2 #820”, where E9-2 is the error code and #820 is the meter count.
13. Proceed to Corrective Actions.
1.4 Corrective Actions
Procedure
Ensure that Initial Conditions are met and that the Initial Actions have been completed. Switch
the main power off, wait 10 seconds, then switch the main power on. The Main Drive Motor
runs.
YN
Perform RAP 2.
The display indicates an upper row of 16 solid squares that remain on for 1 second (Figure 1).
The display is correct.
YN
If machine indicates an error message, see the Error Code Table in section 2. If the display is blank or has garbled text, perform RAP 25.
The Main Drive Motor runs for 8 seconds, then stops.
YN
Perform RAP 16.
The Fuser Fan runs at high speed for 5 seconds, then switches to low speed.
YN
Perform RAP 20.
The LCD Panel will come on again and display “Power On” and the Power On Diagnostic
(POD) software “Version x.xxx” (Figure 2). The display is correct.
YN
Perf orm RAP 25/ RAP 26.
The Control Panel LEDs 1, 2, 3, and 4 turn on momentarily then turn off (blink).
YN
Perf orm RAP 25/ RAP 26.
The display comes on and (*) shows in the upper row (Figure 3). The display is correct.
YN
Perf orm RAP 25/ RAP 26.
A row of (*) (16) form across the top of the display (Figure 4). The display indications are
correct.
YN
Perf orm RAP 25/ RAP 26.
Initial Issue
DocuPrint N2025/N2825
A second row of (*) (16) form across the bottom of the display (Figure 5). The display indications are correct.
YN
Perf orm RAP 25/ RAP 26.
Control Panel LED 1 comes on and remains on.
YN
Perf orm RAP 25/ RAP 26.
The LCD Panel now displays the Controller Software and Version level (x.xx-xx) (Figure 6).
The display indications are correct.
02/2000
1-5
Service Call Procedures
1.3, 1.4
YN
Perform RAP 25/ RAP 26.
The Controller Software Version switches off and the display shows “Initializing . . .“ (Figure 7).
The display is correct.
YN
Perform RAP 25/ RAP 26.
The display now shows “Copyright Xerox Corp.” (Figure 8). The display is correct.
YN
Perform RAP 25/ RAP 26.
Next, “1996-1999 All Rights Reserved” is displayed on the LCD Panel (Figure 9). The display
is correct.
YN
Perform RAP 25/ RAP 26.
Next, “Processing. . .“ is displayed on the LCD Panel(Figure 10). The display is correct.
YN
Perform RAP 25/ RAP 26.
A
Enter Diagnostics and select “Print Menu”. Scroll to “Test Print”. Feed at least 5 test prints from
all availab le trays to the Standard output tray. Test prints were successfully delivered from
each tray.
YN
If the failure occurred with:
MBF. Go to RAP 41.
Tray 1. Go to RAP 49.
Tray 2/3. Go to RAP 7.
2000 Sheet Feeder. Go to RAP 62.
If the Duplex Assembly is installed, select “Duplex On” press Enter [4]. Run at least 5 duplexed
prints. If a Duplex Assembly is not installed, follow the “Y” path. The prints were delivered
successfully.
YN
Go to RAP 56.
If a Offset Catch Tray (OCT) is installed, select “OCT” and run at least 5 prints to the OCT. If an
OCT is not installed, follow the “Y” path. Prints were successfully delivered to the OCT.
YN
Go to RAP 68.
The final display is “Ready”. The display is correct.
YN
Perform RAP 25/ RAP 26.
Press [1] twice to select “Print Menu”, then press and release [2] until “Menu Map” is displayed.
Press Enter [4] to print the “Menu Map”. First, “Processing M enu Map” is displayed, immediately followed by “Processing Tray X". The display is correct.
YN
Perform RAP 25/ RAP 26.
When the Main Driver Motor runs, the motor and all drive gears sound normal.
YN
Perform RAP 29.
Paper is fed from the paper tray to the Registration Roller and is undamaged.
YN
Perform RAP 8.
The paper feeds out of the machine and is undamaged.
YN
Perform RAP 10/ RAP 11.
The print contains readable text.
YN
If the print is black or blank perform IQ RAP 10 or IQ RAP 2. If the text is garbled, Perform RAP 44.
The print quality of the Menu Map is acceptable.
YN
Perform Image Quality Checkout.
Ensure that all normal printer conditions are set i.e. paper loaded, machine in Ready condition,
internet cable connected. Have the customer send a document to the printer. The print is
successful.
YN
Try a sending a document from a different application. The print was successful.
YN
There may be a problem with the print drivers. Have the customer contact Xerox
Customer Support.
There may be a problem with the application software. Have the customer contact Xerox
Customer Support.
Go to Final Actions.
Figure 1
Figure 2
A
Service Call Procedures
1.4
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Initial Issue
DocuPrint N2025/N2825
Figure 3
Figure 9
Figure 4
Figure 5
Figure 6
Figure 7
Figure 10
Figure 11
Figure 12
Initial Issue
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Figure 8
02/2000
1-7
Service Call Procedures
1.4
1.5 Final Actions
Procedure
1. Switch the main power off.
2. Update the tag matrix as required.
3. Reinstall all the covers removed during the service call and complete all required administrative tasks.
4. Clean the covers and ensure all labels are readable.
5. Switch the printer power on. If any of the customer selections were changed return them
to the customer’s preferred settings.
6. Run final prints and verify image quality. For Image Quality problems, go to section 3.
7. Clean the general area.
8. Communicate with the customer to inform them of actions taken and to ensure all problems have been solved.
Service Call Procedures
1.5
02/2000
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Initial Issue
DocuPrint N2025/N2825
2 Status Indicator Repair Analysis Procedures
Introduction ..................................................................................................................... 2-3
Measurements ................................................................................................................ 2-3
Error Code Table
Error Code Table................................... ................. ................. ................. ................ ....... 2-5
Base Printer
RAP 1 AC Power............................................................................................................. 2-11
RAP 2 DC Power ............................................................................................................ 2-12
RAP 3 DC Power Loading............................................................................................... 2-13
RAP 4 C3: Tray Error / Insert Tray 1,2,3......................................................................... 2-14
RAP 5 C5: Add Paper To MBF, Tray 1, 2 or 3)............................................ ................... 2-15
RAP 6 C5: Top Tray Full................................................................................................. 2-16
RAP 7 E1: Paper Jam / Tray To Registration. ................................................................ 2-16
RAP 8 E2-1: Paper Jam / Misfeed.................................................................................. 2-17
RAP 9 E2-2: Paper Jam/ Misfeed Duplex....................................................................... 2-18
RAP 10 E3: Paper Jam / Registration To Fuser ........ ................... .................................. 2-18
RAP 11 E4: Paper Jam / Exit.............................................. ................ ............................ 2-19
RAP 12 System Controller Isolation................................................................................ 2-20
RAP 13 J3: Print Cartridge Not In Position - Install/reset Print Cartridge........................ 2-21
RAP 14 J5: Toner Low.............. ................ ................. ................. ................. ................. .. 2-21
RAP 15 P1: Fuser Pause................................................................................................ 2-22
RAP 16 U1: Motor Fail / Power Off Then On .................................................................. 2-22
RAP 17 U2: ROS Fail / Power Off Then On.................................................................... 2-23
RAP 18 U4: Fuser Failure / Power Off / On .................................................................... 2-23
RAP 19 U6: NVM Fail / Power Off Then On................................................................... 2-24
RAP 20 Fan Abnormal ................................... ................ ................. ................. ............... 2-24
RAP 21 Low Paper Tray 1/2/3 ........................................................................................ 2-25
RAP 22 Paper Size Error .................................................... ................ ................. ........... 2-25
RAP 23 J5 Toner Low..................................................................................................... 2-26
RAP 24 Inoperative Printer ............................................................................................. 2-27
RAP 25 Malfunctioning LCD/LED ................................................................................... 2-28
RAP 26 Inoperative Keypad............................................................................................ 2-29
RAP 27 Erratic Printer Operation.................................................................................... 2-29
RAP 28 Power Supply..................... ................. ................ ................. ................. ............. 2-30
RAP 29 Main Motor Assembly........................................................................................ 2-31
RAP 30 Laser Assembly................................................................................................. 2-32
RAP 31 Fuser Assembly................................................................................................. 2-33
RAP 32 Registration Sensor........................................................................................... 2-34
RAP 33 MBF No Paper Sensor.................................. ..................................................... 2-34
RAP 34 Tray 1 No Paper Sensor.................................................................................... 2-35
RAP 35 Stack Full Sensor............................................................................................... 2-36
RAP 36 E5: MBF Extended / Insert MBF. ....................................................................... 2-37
RAP 37 Size Switch ........................................................................................................ 2-38
RAP 38 Registration Clutch ............................................................................................ 2-39
RAP 39 Turn Roll Clutch Assembly .... ................. ................. ................ ................. ......... 2-40
RAP 40 Tray 1 Feed Solenoid ........................................................................................ 2-41
RAP 41 MBF Feed Solenoid.............................. ................. ................ ................. ........... 2-41
RAP 42 Toner Sensor Assembly.................................... ................. ................ ................ 2-42
RAP 43 HVPS Assembly................................................................................................. 2-42
RAP 44 Electrical Noise.............................. ................. ................. ................ ................. . 2-43
RAP 45 0101 - DIMM 1.................................................. ................. ................ ................ 2-44
RAP 46 0102 - DIMM 2.................................................. ................. ................ ................ 2-45
RAP 47 0101 - DIMM 3.................................................. ................. ................ ................ 2-45
500 Sheet Feeder
RAP 48 Exit Sensor......................................................................................................... 2-47
RAP 49 E2-1: Paper Jam / Misfeed 500 Sheet Feeder................................... ................ 2-47
RAP 50 Low Paper Tray 2 (or Tray 3) 500 Sheet Feeder............................................... 2-48
RAP 51 500 Sheet Feeder Feed Solenoid......................... .................................... ......... 2-49
RAP 52 500 Sheet Feeder Assembly Not Recognized............................... .................... 2-50
RAP 53 500 Sheet Feeder Feed Motor............. ................. ................. ................. ........... 2-51
RAP 54 C3: Tray Out / Install Tray 2 (or Tray 3)............................................................. 2-52
RAP 55 Pre-Registration Sensor........................................................................ ............. 2-52
RAP 56 C5: Add Paper To Tray 2 (or Tray 3) .............................................................. ... 2-53
Duplex Unit
RAP 57 E7: Duplex Jam................. ................................................. ................ ................ 2-55
RAP 58 E5: Top/R Cover................................................................................................ 2-56
RAP 59 C5: Output Tray Full................. ................ ................. ................. ................. ....... 2-56
RAP 60 Duplex Fail................................... ................. ................ ................. ................. ... 2-57
2000 Sheet Feeder
RAP 61 C5: Wrong Size For Duplex ................... ................. ................. ................. ......... 2-59
RAP 62 E2-1:Paper Jam/Misfeed 2000 Sheet Feeder.............................. ...................... 2-59
RAP 63 C3: 2000 Sheet Feeder Carriage Not In Position ....... ....................................... 2-60
RAP 64 C5: Add Paper To 2000 Sheet Feeder ......................... ..................................... 2-60
RAP 65 E5: 2000 Sheet Feeder CVR Open / Please Close CVR................. .................. 2-61
RAP 66 E9:HCF Fail (2000 Sheet Feeder).................. ................................... ................ 2-61
RAP 67 C5: OCT Tray Full.................. ............................................................................ 2-62
Offsetting Catch Tray
RAP 68 E8: OCT Jam ..................................................................................................... 2-63
RAP 69 E5: OCT CVR Open / Please Close CVR.......................................................... 2-64
RAP 70 OCT Motor Assembly................................................................. ........................ 2-64
RAP 71 E9: OCT Fail...................................................................................................... 2-65
RAP 72 Offset Operation Not Performed..................................................................... ... 2-65
RAP 73 OCT Sensor........................................... ............................................................ 2-66
Initial Issue
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02/2000
2-1
Status Indicator Repair Analysis Procedures
Status Indicator Repair Analysis Procedures
02/2000
2-2
Initial Issue
DocuPrint N2025/N2825
Introduction
The Repair Analysis Procedures section is used to isolate and identify problems to a faulty
component or subassembly. It contains the Introduction, display message table, error code
table and the Repair Analysis Procedures (RAPs).
Measurements
Power and signal grounds are connected to frame ground, therefore all circuit troubleshooting
can be performed using the metal frame (chassis) as the grounding point. If more information is
needed to locate connectors or test points, refer to section 7.
Use the Display Messages and Error Codes tables when messages are displayed or error
codes are printed in a report.
The Repair Analysis Procedures (RAPs) are acce ssed from Sect ion 1, system checks or additional checks. There are two types of RAPs: Status Indicator (SI) RAPs, contained in this section, and Image Quality (IQ) RAPs, located in Section 3.
RAPs will normally isolate a problem to a specific component or s ubassembly, excluding the
wire harnesses.
In the Y/N (Yes/No) steps of the RAPs, a Yes/No response will either lead you to the next step
or will indicate a corrective action. When the indicated corrective action has been completed,
go to Section 1 and restart the System Check to verify that the problem has been corrected.
Unless otherwise specified, the following voltage tolerances are used within this section: Table
1
Table 1 Voltage Measurements
Stated Measured
+3.3 VDC +3.0 to 3.6 VDC
+5.0 VDC +4.8 to +5.2 VDC
+24.0 VDC +21.6 to +26.4 VDC
0.0 VDC Less than +0.5 VDC
Initial Issue
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02/2000
2-3
Status Indicator Repair Analysis Procedures
Introduction, Measurements
Status Indicator Repair Analysis Procedures
Introduction, Measurements
02/2000
2-4
Initial Issue
DocuPrint N2025/N2825
Error Code Table
Comments On LIne Message Fault History Entry Diagnostic Message Error Description Action
2000 Sheet Feeder
installed as Tray 2
2000 Sheet Feeder
installed as Tray 3
Table 1 Error Code Table
IOT NVM Fail
Power Off/On
Motor Failure
Power Off/On
Laser Failure
Power Off/On
Fuser Failure
Power Off/On
Fan Failure
Power Off Now
Close Offset Door E5: OCT Rear Door OCT rear door interlock switch is open. Close OCT rear door
Close Tray 2
Rear
Close Tray 3
Rear
U6 U6: NVM Fail 1. A read error is detected during
power on.
2. A write error is detected during
write to the Nonvolatile Memory.
U1 U1: Motor Fail Motor Fail signal is declared 0.75 sec-
onds after start of Main Motor.
U2 U2: ROS Fail 1. Laser Signal intervals are longer
than the Ready time interval 20 seconds after the start of Laser warm
up.
2. The laser power does not reach the
value in NVM when the laser diode
is switched on after the start of
Laser warm up.
3. Laser signal intervals become
longer than the Fail time interval
after Laser warm up is completed.
U4: Fuser Fail 1. Fuser temperature drops below the
set temperature after the Fuser
warm up is complete.
2. Fuser warm up does not complete
within 110 seconds.
3. Thermistor circuit is detected to be
open.
4. Fuser temperature rises above the
set temperature.
5. Heat rod is on for 10 seconds when
the Main Drive Motor is stopped,
after the Fuser warm up is completed.
U5 U5: Fan Fail 1. Fuser Fan has failed.
2. LVPS Fan has failed.
E5: HCF Cover 2000 Sheet Feeder rear cover interlock
switch is open
E5: HCF Cover 2000 Sheet Feeder rear cover interlock
switch is open
Power Off and On
Go to RAP 19
Power Off and On
Go to RAP 16
Power Off and On
Go to RAP 17
Power Off and On
Go to RAP 18
Check the Fuser Fan and the
LVPS Fan.
Power Off and On
Go to RAP 20
Go to RAP 69
Close 2000 sheet feeder rear
cover
Go to RAP 65
Close 2000 sheet feeder rear
cover
Go to RAP 65
Initial Issue
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02/2000
2-5
Status Indicator Repair Analysis Procedures
Error Code Table
Table 1 Error Code Table
Comments On LIne Message Fault History Entry Diagnostic Message Error Description Action
Close Covers E5: Top/R Cover 1. Top cover interlock is open.
Insert MBF E5: MBF Extend MBF Assy. is not closed. Close MBF
Install
Print Cartridge
Duplex Jam
Open Rear Cover
Clear Paper Path
Exit Jam-Open
Rear & Top Cover
Remove Print Cartridge
Clear Paper Path
Paper Jam
Open Top Cover
Remove Print Cartridge
Clear Paper Path
MBF misfeed Paper Jam
Open Top Cover
Lift /Extend MBF
Remove All Paper
2. Rear cover interlock is open.
J3: EP Cartridge 1. Print Cartridge is not installed
2. The installed Print Cartridge is not
the correct one.
E7-1 E7: Duplex Jam 1. Duplex Sensor is not actuated
within the time after the start of the
Duplex drive motor in reverse.
2. Duplex sensor is being actuated at
power up.
3. Duplex Sensor is on when the interlock is closed.
E4-0 E-4: Exit Jam 1. Exit sensor is not deactuated within
time after it is actuated.
2. Exit sensor is being actuated at
power up.
3. Exit Sensor is ON when the interlock is closed.
4. Exit Sensor turns from OFF to ON
at Erase Cycle.
E3-1 E3: Reg. Jam Exit Sensor did not actuate within time
after the Registration clutch is actuated.
E2-1M E2-1 Misfeed Jam 1. Simplex printing: Reg. Sensor is
OFF when the specified time has
passed timing from Feed Roll ON.
2. Printing from 2000 Sheet Feeder:
Reg. Sensor is OFF when the timing is after receiving Feed_Run status.
Close Top Cover
Close Rear Cover
Go to RAP 58
Install the Print Cartridge, or
replace with the correct Print
Cartridge
Go to RAP 13
Open the Rear Cover and
remove any paper.
Go to RAP 57
Open Top Cover, remove EP
Cartridge and remove any
paper.
Go to RAP 11
Open Top Cover, remove EP
Cartridge and remove any
paper.
Go to RAP 10
Open Top Cover or Feeder and
remove the sheets. Then close
the cover.
Go to RAP 8
Tray 1 Misfeed Tray 1 Jam
Open Tray 1
Lift/Extend MBF
Open Top Cover
Remove Printery
Clear Paper Path
Status Indicator Repair Analysis Procedures
Error Code Table
E2-11 E2-1 Misfeed Jam 1. Simplex printing: Reg. Sensor is
OFF when the specified time has
passed timing from Feed Roll ON.
2. Printing from 2000 Sheet Feeder:
Reg. Sensor is OFF when the timing is after receiving Feed_Run status.
02/2000
2-6
Open Top Cover or Feeder and
remove the sheets. Then close
the cover.
Go to RAP 8
Initial Issue
DocuPrint N2025/N2825
Table 1 Error Code Table
Comments On LIne Message Fault History Entry Diagnostic Message Error Description Action
Tray 2 misfeed with
500 Sheet Feeder
installed as Tray 2
Tray 3 Misfeed with
500 Sheet Feeder
installed as Tray 3
Tray 2 misfeed with
2000 Sheet Feeder
installed as Tray 2
Tray 3 misfeed with
2000 Sheet Feeder
installed as Tray 3
Jam in the OCT Offset Jam
Tray 2 Jam
Open Tray 2
Lift/Extend MBF
Open Top Cover
Remove PrintCart
Clear Paper Path
Tray 3 Jam
Open Tray 3
Lift/Extend MBF
Open Top Cover
Remove PrintCart
Clear Paper Path
Tray 2 Jam
Open Tray 2
Open Rear Trader
Clear Paper Path
Tray 3 Jam
Open Tray 3
Open Rear TrayDr
Clear Paper Path
Duplex Jam
Open Rear Cover
Clear Paper Path
Open Rear Cover
Open Offset Door
Clear Paper Path
Paper Jam
Open Top Cover
Lift/Extend MBF
Remove PrintCart
Clear Paper Path
E2-12 E2-1 Misfeed Jam 1. Simplex printing: Reg. Sensor is
OFF when the specified time has
passed timing from Feed Roll ON.
2. Printing from 2000 Sheet Feeder:
Reg. Sensor is OFF when the timing is after receiving Feed_Run status.
E2-13 E2-1 Misfeed Jam 1. Simplex printing: Reg. Sensor is
OFF when the specified time has
passed timing from Feed Roll ON.
2. Printing from 2000 Sheet Feeder:
Reg. Sensor is OFF when the timing is after receiving Feed_Run status.
E2-12 E2-1 Misfeed Jam 1. Simplex printing: Reg. Sensor is
OFF when the specified time has
passed timing from Feed Roll ON.
2. Printing from 2000 Sheet Feeder:
Reg. Sensor is OFF when the timing is after receiving Feed_Run status.
E2-13 E2-1 Misfeed Jam 1. Simplex printing: Reg. Sensor is
OFF when the specified time has
passed timing from Feed Roll ON.
2. Printing from 2000 Sheet Feeder:
Reg. Sensor is OFF when the timing is after receiving Feed_Run status.
E2-D E2-2: Misfeed Jam Registration Sensor did not actuate
within time after the actuation of the
Duplex Motor in reverse.
E8-1 E8-OCT Jam 1. OCT sensor did not actuate within
time after the actutation of the Exit
sensor.
2. OCT sensor is not deactuated
within time after actuation of OCT
Sensor.
3. OCT sensor is actuated at power
on.
E1-1 E1: Reg. Jam 1. Registration Sensor did not deactu-
ate within time after actuation of
Registration sensor.
2. Registration sensor is actuated at
power on.
3. Registration is actuated during
warm up cycle or an erase cycle.
Open Top Cover or Feeder and
remove the sheets. Then close
the cover.
Go to RAP 49
Open Top Cover or Feeder and
remove the sheets. Then close
the cover.
Go to RAP 49
Open Top Cover or Feeder and
remove the sheets. Then close
the cover.
Go to RAP 62
Open Top Cover or Feeder and
remove the sheets. Then close
the cover.
Go to RAP 62
Open Rear Cover and remove
any paper.
Go to RAP 9
Open OCT rear door and
remove any paper.
Open Rear cover and remove
any paper.
Go to RAP 68
Open Top Cover, remove EP
Cartridge, Lift and Extend MBF
assy and remove any paper.
Go to RAP 7
Initial Issue
DocuPrint N2025/N2825
02/2000
2-7
Status Indicator Repair Analysis Procedures
Error Code Table
Table 1 Error Code Table
Comments On LIne Message Fault History Entry Diagnostic Message Error Description Action
2000 Sheet Feeder
installed as Tray 2
2000 Sheet Feeder
installed as Tray 3
Duplex Unit Fail or
Removed
Offset Bin Fail
Power Off/On
Tray 2 Failure
Power Off/On
Tray 3 Failure
Power Off/On
Paper Size Jam
Open Rear Cover
Insert T r ay 1 C3:Tray 1 Error Tray 1 is not detected in printer. (all paper
Insert T r ay 2 C3: T ra y 2 Error Tra y 2 is not detected in printer. (all paper
Insert T r ay 3 C3: T ra y 3 Error Tra y 3 is not detected in printer. (all paper
Load Tray 1 C5:Tray 1 Empty Tray 1 is out of paper Load paper into Tray 1
Load Tray 2 C5:Tray 2 Empty Tray 2 is out of paper Load paper into Tray 2
Load Tray 3 C5:Tray 3 Empty Tray 3 is out of paper Load paper into Tray 3
Load MBF C5:MBF Empty MBF is out of paper Load paper into MBF
Remove Output
from St. Bin
Remove Output
from Offset Bin
Toner Low J5:Toner Low Toner Low is detected after 10 prints
Memory Failure
Power Off/On
E9-1 E9:Duplex Fail Duplex module removed while power is
on.
E9-2 E-9:OCT Fail OCT removed while power is on. Reinstall OCT
E9-3 E-9:HCF Fail 2000 Sheet Feeder remov ed while power
is on.
E9-3 E-9:HCF Fail 2000 Sheet Feeder remov ed while power
is on.
EO:HCF Elevator 1. 2000 Sheet Feeder elevator did not
reach home position within the prescribed time.
2. Paper level sensor on when 2000
Sheet Feeder Tray is Opened.
PSE-1 Paper Size Error There is a conflict between the size of
the paper, which is detected by the Size
Switches, and the length of paper the
printer detects by the length of time the
Registration Sensor is actuated.
size switches not actuated)
size switches not actuated)
size switches not actuated)
C5: T op T r ay Full Top Tray is declared full when 5 prints are
delivered to the top tray after the Full
Stack sensor is actuated.
C5:OCT Tray Full 5 prints are delivered to the top tray after
the OCT Full Stack sensor is actuated.
while toner sensor is on.
ESS-M N/A Controller memory has failed (32 me on
board).
Reinstall Duplex Module
Go to RAP 60
Go to RAP 71
Reinstall HCF
Go to RAP 66
Reinstall HCF
Go to RAP 66
Open and close 2000 Sheet
Feeder paper tray.
Correct the mismatch
Go to RAP 22
Install Tray 1
Go to RAP 4
Install Tray 2
Go to RAP 4
Install Tray 3
Go to RAP 4
Go to RAP 5
Go to RAP 5
Go to RAP 5
Go to RAP 5
Empty Top Tray
Go to RAP 6
Empty OCT Tray
Go to RAP 67
Replace Print Cartridge
Go to RAP 14
Go to RAP 23
Po wer Off/On
Remove Options
Replace System Controller
PWB (REP 8.1)
Go to RAP 12
Status Indicator Repair Analysis Procedures
Error Code Table
02/2000
2-8
Initial Issue
DocuPrint N2025/N2825
Table 1 Error Code Table
Comments On LIne Message Fault History Entry Diagnostic Message Error Description Action
NV Memory Fail
Power Off/On
Disk Error
Format Disk
Init Failed
Disk Locked
Format Failed
Disk Locked
Control Panel Message
0001 - System Controller 1 System Controller Board major failure. Go to RAP 12.
0001 - BASE RAM 2 System Controller Board RAM failure. Go to RAP 12.
0001 - BASE ROM 3 System Controller Board boot ROM. Go to RAP 12.
0001 - ASIC 4 System Controller Board ASIC failure . Go to RAP 12.
0001 - TIMER 4 System Controller Board Timer failure. Go to RAP 12.
0001 - PWPM 5 System Controller Board PWPM failure. Go to RAP 12.
0001 - DMA 5 System Controller DMA failure. Go to RAP 12.
0001 - COMM 6 System controller parallel port failure, USB port failure, E-
0001 - USB 6 Replace the System Controller PWB (REP 8.1)
1000 - IOT 8 System Controller - IOT handshake failure.
0010 - DISK 9 Hard disk failure.
0101 - DIMM1 10 DIMM board 1 failure. Go to RAP 45.
0102 - DIMM2 11 DIMM board 2 failure. Go to RAP 46.
0103 - DIMM3 12 DIMM board 3 failure. Go to RAP 47.
2000 - XIE RAM 15 System Controller Xerox Image Enhanced PWPM failure.
2010 - XIE PWPM 15 System Controller Xerox Image Enhanced PWPM failure.
ESS-N N/A Controller NVM Failure P ower Off/On
D-1 N/A Hard Drive error was detected. Power Off/On
D-2 N/A Cannot format disk, disk locked via PJL
or SNMP Command.
D-3 N/A Cannot put disk in factory default attempt
to initialize disk after it is locked.
Table 2 System Controller Error Code Table
LED # blinks
Followed by 1 sec. off Comment
Net Port Failure.
Replace System Controller PWB (REP 8.1)
Remove and reinstall the System Controller PWB (REP
8.1).
Replace the System Controller PWB (REP 8.1).
Replace the Print Engine Controller PWB (REP 8.5).
Format Hard Disk (see Reset Menu GP 3.3).
Replace the Hard Disk (PL 9.1).
Replace the System Controller PWB (REP 8.1).
Replace the System Controller PWB (REP 8.1).
Replace the System Controller PWB (REP 8.1).
Replace System Controller
PWB (REP 8.1)
Format Hard Drive (See Reset
Menu GP 3.3)
Replace Hard Drive (PL 9.1)
Replace System Controller
PWB (REP 8.1)
Customer Unlock Disk
Replace Hard Disk (PL 9.1)
Customer Unlock Disk
Replace Hard Disk (PL 9.1)
Initial Issue
DocuPrint N2025/N2825
02/2000
2-9
Status Indicator Repair Analysis Procedures
Error Code Table
Table 2 System Controller Error Code Table
Control Panel Message
2020 - XIE VDMA 15 System Controller Xerox Image Enhanced VDMA failure.
3000 - Token Ring
3000 - Serial
3000 - E-Net (10 Base 2)
5000 - Memory None Memory size not large enough to load the system software
LED # blinks
Followed by 1 sec. off Comment
Replace the System Controller PWB (REP 8.1).
16 Replace the appropriate network card (PL 9.1).
Replace System Controller PWB (REP 8.1).
Download Data.
Replace System Controller PWB (REP 8.1).
Status Indicator Repair Analysis Procedures
Error Code Table
02/2000
2-10
Initial Issue
DocuPrint N2025/N2825
RAP 1 AC Power
Initial Actions
Disconnect the AC power cord from the wall outlet.
WARNING
Improper connection of the grounding conductor can result in the risk of electrical
shock. The following must be observed:
• Never use a ground adapter plug to connect the machine to a power source.
• Never attempt any maintenance function which is not specifically called out in the
service procedures.
• Never remove any covers which are fastened with screws, unless so instructed in
the service procedures.
CAUTION
If any of the voltage measurements are not as specified in the following steps, the cause must
be corrected. Caution the customer NOT to connect the machine to the wall outlet. Advise the
customer that a licensed electrician must correct the wiring. Do not attempt to correct the wiring yourself. If you later find the condition has not been corrected, inform your manager in writing of the improper wiring.
Procedure
Perform one of the following line voltage checks:
US, XCI, and AO (115 VAC) Figure 1. Perform the following:Measure the AC voltage between
AC Line and Neutral, between AC Line and Ground, and between AC Neutral and Ground. The
voltage between Line and Neutral and between Line and Ground is 104 to 127 VAC and the
voltage between Neutral and Ground less than 3 VAC.
XL, UK and AO (220 VAC) Figure 2. Perform the following:Measure the AC voltage between
Line and Neutral, between Line and Earth/Ground, and between Neutral and Earth/Ground.
The voltage between Line and Neutral and between Line and Earth/Ground is 216 to 264 VAC
and between Neutral and Earth/Ground is less than 3 VAC.
Figure 2 XL, UK, and AO (220 VAC) Outlet.
XL, Europe (220 VAC) Figure 3. Perform the following: Measure the AC voltage between the
supply pins, then between a supply pin and earth, then between the other supply pin and earth.
The voltage is 196 to 244 VAC between the supply pins and between one of the supply pins
and earth. Between the other supply pin and earth is less than 3 VAC.
Figure 3 XL, Europe (220 VAC) Outlet.
Initial Issue
DocuPrint N2025/N2825
Figure 1 US, XCI, and AO (115 VAC) Outlet.
The voltage measured is correct.
YN
Inform the customer of insufficient voltage or improper wiring.
Check the continuity through all connections of the power cord. The measurement is less
than 10 ohms for each connection.
YN
Replace the power cord (PL 9.2) as applicable.
Perf orm RAP 2.
02/2000
2-11
Status Indicator Repair Analysis Procedures
RAP 1
RAP 2 DC Power
This procedure is used to troubleshoot the Low Voltage Power Supply.
Procedure
Perf orm RAP 1 before starting this RAP. If RAP 1 checks out OK, switch the main power off and
disconnect the printer power. Remove the Lower Rear Cover (REP 1.7). Connect printer power.
Switch the printer power on. Measure the voltage on the LVPS between P/J167 pins 1 and 3.
The voltage matches the line voltage.
YN
Replace the AC Input Assembly (REP 8.8).
Measure the voltage between the bottom of Fuse F101 and P/J167 pin 3. The voltage
matches the line voltage.
YN
Switch the main power off. Replace fuse F101. Switch the main power on. Measure the
voltage between the bottom of Fuse F101 and P/J167 pin 3. The voltage matches the
line voltage.
YN
Replace the LV PS (R EP 8.6).
Problem Solved.
Measure the voltage between LVPS P/J162 pin 3 and frame ground. The voltage is +24VDC.
YN
On the LVPS, measure the voltage between P/J162 pin 1 and frame ground. The voltage
is +24VDC
YN
Replace the LV PS (REP 8.6).
A
Return to Initial Actions or to the procedure that sent you here.
Check the Top Cover and the printer Upper Rear Cover. Both covers are properly
closed and actuating the interlock switches.
YN
Repair or replace the defective cover/interlock switch as necessary.
Check the continuity through the interlock switches. Replace if necessary (REP 7.5/REP
10.13).
Check the voltages listed in Table 1.
Table 1 LVPS
Red Lead Black Lead Voltage
P/J161 pin 10 Frame Ground +5.0VDC
P/J161 pin 11 Frame Ground +3.3VDC
P/J161 pin 3 Frame Ground +24.0VDC
All voltages in Table 1 are correct.
YN
Go to RAP 3.
A
Status Indicator Repair Analysis Procedures
RAP 2
02/2000
2-12
Initial Issue
DocuPrint N2025/N2825
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